American Journal of Systems Science 2012; 1(1): 7-16

DOI: 10.5923/j.ajss.20120101.02

Recent Developments in Rapier Weaving Machines in

Textiles
Subhankar Maity1, Kunal Singha1,*, Mrinal Singha2

1
Department of Textile Technology, Panipat Institute of Engineering & Technology, Harayana, India
2
Department of Pharmaceutical Chemistry, CU Shah College of Pharmacy & Research, Gujarat, India

Abstract This paper reviews the recent developments in rapier weaving and addresses the challenges that face the
weaving industry. The paper sheds the light on how the weaving machine manufacturers and woven fabric producers might
strengthen the weaving industry by further advanced the rapier technology with the help of electro-mechanics, electronics,
microprocessors, information technology and their application to the production of woven fabrics.
Keywords Rapier, Electro-Mechanics, Electronics, Microprocessors, Information Technology, Woven Technology

Smith of Salford was granted a patent to eliminate the shuttle.

1. Introduction
Rapier weaving today exists in diversified forms. During
the last two decades the developments in rapier weaving
have been carried out in a rapid continuous way. Rapier
weaving machine produces top- quality fabrics from spun
yarns such as cotton-wool, camel hair, silk, synthetic fibers
and fancy yarns. Today’s rapier weaving machine has be-
come fast and exceptionally flexible. It offers a choice of
various reed widths, shedding motions, selvedges and filling
insertion colors.
This makes it suitable for weaving an extended range of
articles: fashion fabrics, shirting, denim, suiting, industrial or
furnishing fabrics, in one to eight or twelve filling colors or
yarns, with a maximum weight of 500 g/m2. Today’s rapier
weaving machine is designed with modern electronics, with
total automation of weaving and central microprocessor
control system, also ensuring maximum reliability, amazing
user-friendliness, ease-of operation, shorter style changing
time, excellent fabric quality, low energy consumption, and
optimized insertion cycle for unequalled industrial
speed[1-4].
2. History of Rapier
In the past 150 years weaving machinery has gone through
the most radical changes. Although the invention of the fly
shuttle by John Kay-which doubled the production of hand
loom - came in 1733, the development of shuttleless loom,
starting with the rapier loom, goes back to 1844, when John
* Corresponding author:
kunalsingha28@gmail.com (Kunal Singha)
Published online at http://journal.sapub.org/ajss
Copyright © 2012 Scientific & Academic Publishing. All Rights Reserved
Subsequent patents were taken out by Phillippe and Maurice
in 1855, W.S. Laycock in 1869, W.Glover in 1874[7]. Rigid
rapiers were invented in 1870 and perfected by O. Hal-
lensleben in 1899. The main breakthrough came in 1922
when John Gabler invented principle of loop transfer in the
middle of the shed [8-10]. Flexible rapiers of the type used
today were proposed in 1925 by R.G.Moya of Barcelona,
based on a Spanish patent applied for in 1924. In 1939, an-
other inventor, R.Dewas, introduced the novel idea of
grasping the weft at its tip by the giver or a carrier rapier, and
then transferring it to the taker or a receiver, in the middle of
the shed. In the period up to the beginning of the World War
2 many patents were applied for, but it was only in the 50s
and 60s that rapier weaving finally become commercialized
and since then has made highly significant progress in
achieving the present weft insertion rate of 1,500 m/min
plus[11].
3. History of Development of Rapier
Technology
Rapier looms vary greatly in both the general strategies of
their design, such as the choice of method used to transfer the
weft between the rapiers and the types of rapier used- rigid,
flexible or telescopic- and in details of mechanism used.
These machines find preferential use in the production of
with fashion-appeal compared to other methods of weft
insertion which are mainly suitable for weaving staple items
with limited fashion-appeal. Ease of multicolor weft inser-
tion is fully exploited by rapier looms - many can insert up to
12 colors in any pick-at-will patterning sequence, including
their ability to deal with a wide range of yarns and fabric
types. The positive rapier drives enables heavy or otherwise
difficult yarns to be inserted. The rigid rapier system of weft
8 Subhankar Maity et al.: Recent Developments in Rapier Weaving Machines in Textiles

insertion has the advantage of positive thread transfer in the
centre of the shed without any need for guiding the rigid
rapiers through the shed and without making contact with the
warp thread. However this is at the cost of occupying more
floor space, which causes reed width of the rigid rapier to be
limited. The flexible rapier system of weft insertion has the
reputation of being most adaptable and most applicable. The
outstanding feature of flexible rapier machine is its signifi-
cant increase in weft insertion rate, greater reed width
(460cm), versatility and adaptability. In the last 15 years or
so the design of the rapier machine has been revolutionized
by new innovations, engineering walkthroughs, automation
in processes, introduction of computer technology, elec-
tronics and CAD-CAM systems. The weaving industry on
the whole has entered a new era of electronics, microproc-
essors, information technology and their application to the
production of woven fabrics. Incorporation of electronic
devices and system to weaving machines has become almost
inseparable part of the machine. Developments, particularly
of microprocessors, have revolutionized the design of the
rapier weaving machines, including the weft propulsion
technology. The weft insertion elements have been made
smaller and lighter in weight[2,4,26-28].
4. Development in Filling Insertion
In the area of filling insertion there are a lot of develop-
ments and implementation has been done since few years.
These are discussed following.
timing for presenting for filling yarn is perfectly synchro-
nized with machine speed and weave pattern.
● The course of filling yarn is low and remains constant.
● The filling presenter also provides ideal position for re
threading.
● The modules of quickstep are interchangeable.
4.2. Picking Speed
In jacquard weaving upto 12 weft colors give a wide va-
riety of patterning option. The G6500 offers a machine speed
of upto 700 rpm and a maximum weft insertion rate of 1620
m/min[6,8].
4.3. Secure Filling Transfer
During centre transfer from the left-hand to the right-hand
rapier, the filling is positively controlled and thus securely
transferred. The filling is released after the rapier has exited
the shed in the open shed position and under absolutely
control conditions. In Dornier rapier weaving machine, the
highest peak yarn tension is extremely low due to the low
rapier speed and positive control. Soft thread clamps with
hard metal inserts and precision controlled transfer enable
even coarse filament yarns of 2200 dtex with 450 filaments
to be securely clamped and inserted[6,7].

4.1. Versatility in Colour Insertion by Electronic

Insertion
The weft color selectors of today’s rapier weaving ma-
chine are microprocessor controlled, compact sized ones and
can be available in 16, 12, 8, 4 or 2 colors. Picanol developed
the Quick Step filling presenter, operates with independent
module, each consisting of an electronically controlled
stepper motor with presenter needle. The color and weave
pattern are microprocessor or jacquard controlled. After the Figure 1. Secure filling transfer[7]
left gripper has taken the presented yarns, the Quick Step
needle returns to an intermediary position, so the course of
the filling yarn is straight and the tension of the yarn is low
and remains constant. The Quick Step filling presenter has
several advantages. It is monitored by the machine micro-
processor, so the timing for the presentation of the filling
yarn is perfectly synchronized with the machine speed and
the weave pattern. The filling presenter also provides the
ideal position for rethreading. The modules of the Quick Step
are interchangeable and there are no mechanical drives, so no
maintenance or lubrication is required[6,7]. Dornier offers
the Electronic Color Selector (ECS), and the electronic fill-
ing tension device with integrated filling stop motion (EFC),
are based on state-of-the-art stepping motor technology and
are controlled by an external CAN-BUS[6,7,31].
Advantages of the system are;
● It is monitored by weaving machine microprocessor so Figure 2. Versatile rapier [7]
 American Journal of Systems Science 2012; 1(1): 7-16
4.4. Versatility of Rapier Gripper
A new generation rapiers capable of handling even the
most difficult of yarns, typical of the latest trends in fashion
fabrics. The rapiers are lightweight and compact and
mounted at the centre of gravity on the ribbons to reduce
wear to the minimum and guarantee maximum accuracy in
movement. It facilitates the processing of the widest range of
yarn types and counts – from fine silk yarns through glass
rovings to the coarsest effect yarns. The count range lies
between 0.77 tex and 3333 tex. The weft exchange also takes
place in slow speed, thus making life far easier for those
involved in adjusting the machine setting and at machine
start-up[6,7].
4.5. Free Flight Rapier
Free Flight means that hooks no longer guide the rapier
tape, so the hooks can no longer damage the yarns by diving
into the warp. Picanol developed Free Flight Rapier in their
GamMax rapier-weaving machine, which has been specially
developed for weaving delicate fabric. The machine has a
covered race board for gentle treatment of the warp yarns
during beat-up. The Free Flight version of GamMax is es-
pecially useful for production of lining, voile, curtains, up-
holstery fabrics, industrial fabrics, high- twist crepe, air-bags,
computer ribbon, spinnaker (soil cloth), glass and Kev-
lar[5,6].
4.6. Light and Small Rapier Head
The new lightweight guided gripper version enables
higher speeds, and since the easier presentation into the
gripper clamp requires less filling tension, the number of
filling stops is reduced. The light gripper is also smaller,
which results in a smoother entrance of the gripper in the
shed, ensures less friction on the warp yarns. This reduces
the warp breaks[6].
4.7. Versatile and Synchronized Weft Cutter
A perfectly efficient weft cutter mechanism is required for
use of a wide range of yarn in rapier weaving machine.
Leonardo has the weft cutter having direct gear drive, en-
suring constancy and precision and reducing yarn wastage.
The rapier head inserts any kind of weft. With the "RotoCut"
in G6500, electronically controlled weft cutter, the timing of
weft cutting is optimized. The "RotoCut" always cuts the
weft at the best possible moment, irrespective of yarn type
and material[6,8].
4.8. Electronic Filling Tension Controller
It controls the filling brake ensures a current yarn tensions
at any time during insertion cycle. It can be installed for each
channel between the pre-winder and entry of fixed main
nozzle. It has been designed to slow down the filling at the
end of insertion. It thus significantly reduces the peak tension
of the pick at the end of the insertion and decrease the ten-
dency of pick to bounce back in the shed. As a result of
which the filling tip is stretched correctly with the following
9
features;
● Lower peak tension in filling yarn.
● Reduced tendency of filling to bounce back.
● Inserted pick can be stretched more easily.
● Adjustments are done by means of machine keyboard
and display.
● The settings can be adopted for each filling yarn.
● Fewer filling breaks.
● Fewer machine stops.
● Better fabric quality.
● Higher productivity of machine and staff.
● Weaker filling yarn can be used.
● Correct setting of filling waste length and consequently
less waste.
In Picanol GamMax rapier weaving machine, each
prewinder is equipped with Programmable Filling Tensioner
(PFT). This PFT is microprocessor controlled and ensures
optimum yarn tension during the complete insertion cycle.
Reducing the basic tension is an important advantage when
piecing up weak yarn, while adding tension is an advantage
at transfer of the yarns and avoids the formation of loops.
This ensures weaving of strong or weak yarns at even higher
speeds and also drastically reduces the amount of filling
stops and reduces the waste length[3,5,6].
4.9. Prewinder Switch-off Monitoring
A piezo-electric filling detector stops the machine in case
of a filling break at prewinder. Picanol offers PSO
(Prewinder Switch off) system. The machine continues
weaving even in case of a filling break occur on the packages
or the prewinder. The prewinder signals the filling breaks
and simply switches to the single channel operation instead
of two channels[6,8].
4.10. Filling Detection at the End of Insertion
When weaving lively yarns, FDEI (Filling Detector End
of Insertion) checks the presence of filling at the end of
insertion. This system detects short pick or rebounding fill-
ings and prevents faults in the fabrics at the right hand side.
Picanol developed this system[6].
4.11. Pick Finding
At the filling breaks the machine stops and only the har-
nesses are moved automatically to free the broken pick for
removal by the weaver. The requirements that pick finding
position is reached with a minimum of reed movements
through the beat-up line. In GamMax, the pick finding is
simply done by the Sumo motor at slow speed[1,5,7].
4.12. Rapier Cleaning Device
A special air blow system with solenoid valve control to
the rapier cleaning devices that ensures cleaning of the rapier
when the left hand rapier passes this every time. It produces a
modulated blast of air to guarantee better cleaning and thus
improve weaving performance. Leonardo offers this Rapier
cleaning device[6].
10 Subhankar Maity et al.: Recent Developments in Rapier Weaving Machines in Textiles
5. Developments in Shedding
Mechanism
There are several development has been taking place in
the recent time in the rapier loom like;
5.1. Versatility
Today rapier weaving machine can be equipped with a
tappet motion with upto 10 healds; positive cams, maximum
8 harness frames, 12 mm pitch; electronic rotary dobby for
12,20 or 24 frames, 12 mm pitch; or an electronically con-
trolled jacquard machine having upto 20,000 hooks[2,3].
5.2. Controllable Shed Geometry
Modern rapier weaving machine offers shed opening free
from setting and optimization of the shed geometry. The
shed opening is easily adjusted to suit the style in production.
The symmetrical shed geometry and very small shed offer
lower stress on both the warp threads and filling. Automatic
shed leveling on dobby and jacquard prevents starting mark
due to yarn stretch caused by a stop at open shed. In Gam-
Max, the shed opening offers optimum geometry combined
with a wide range of backrest position. Small or large shed
opening can be easily set to suit the article being woven[6,9,
29-30].
5.3. Electronic Setting of Shed Crossing
A unique Picanol feature using AKM allows the weaver to
control the aspect and hand of the fabric without even
touching the drive chain. A few simple keystrokes on the
display are all it takes to let GamMax reset its crossing points.
The fabric quality can be checked and the setting copied to
Figure 3. Synchronized Electronic Let-off and Take-up mechanism[7]
another machine within a short time[6,9].
5.4. Variable Shed Geometry
The variable shed opening angles and setting options re-
sult in unprecedented precision of the shed geometry in
rapier G6500 machine. The shed closure timing is easily set
at the touch-screen terminals[8].
5.5. Shortest Drive Path
Picanol offers direct driven of the main shaft and the
shedding motion through the main motor. This results in
reduced noise levels and consumes less energy[9].
6. Development in Let-off Mechanism
The electronic motor driven let-off supplies the loom with
necessary wrap yarn, maintaining the yarn tension constant
from full beam to empty beam. Let-off speed is automati-
cally calculated in context with loom speed, weft density,
wrap beam diameter & close loop tension control. Accurate
synchronization with main motor in forward & reverse di-
rection in addition with remarkable latest features supports to
minimize the beginning & ending marks thus, enhancing the
grade & quality of the fabric. Besides this, it enables cram-
ming/density design possible[10]. The let-off & take up is
synchronized rigidly with main motor in forward as well as
reverse direction. With the take up electronic system the weft
density variation doesn’t need any more mechanical inter-
ruptions on the loom, it just need setting parameters on the
fly of the key.
 American Journal of Systems Science 2012; 1(1): 7-16
The great advantages are:
● Cramming pick finding- forward & reverse.
● Controlled synchronized movement during start, stop &
running
● It boost quality & efficiency of the product
● A great value addition to the weaving machine.
The accurateness in settings & functioning introduces an
easy way to adjust weft density for highest fabric weight &
least yarn consumption. The most remarkable thing is that it
creates lots of alternatives for the weaver to manage the
fabric marks & quality. In addition pc connectivity & inter-
net options offer loom data monitoring either locally as well
as from a remote place too. The let-off motion is electroni-
cally controlled with load cell for different setting. Warp
tension can be set by digital system[11-13].
Warp beams with 800, 1000 and 1200 mm with following
configuration can be available:
● Twin beam with differential drive.
● Twin beam with bilateral let- off.
● Double simple beam or double twin beam.
Somet Thema Super Exel offers electronic warp let-off
and fabric wind-up by means of an electronic gear system[7,
14]. The precision of the electronic gear system synchronizes
with the fabric take-up. A double warp let-off for heavy
fabrics ensures microprocessor controlled constant warp
tension. This guarantees easy let-off of both half-beams. The
reading system of the warp tension is independent for the two
beams.
In Leonardo, the warp let-off is optimized by a unique and
extremely versatile backrest support ensuring significant
advantages even in the case of heavy weight fabric. Leo-
nardo is also equipped with a twin beam version, with in-
dependent drive system for the two beams, ensuring constant
warp tension[6,7,9]. Let-off and take-up motions are iden-
tical in construction, simplifying handling as well as spare
part inventory. Each motion utilizes a resolver as the meas-
uring system, connected together with the sensor to a control
circuit. Even when weaving with twin beams the precision of
the entire system is maintained. The accuracy of setting the
warp tension on the display is in the region of 1 gram and in
the case of the take-up, up to 0.01 pick/cm[7,15].
7. Developments in Take-Up Mechanism
The take-up motion is also electronically controlled and
synchronized with let-off motion. Inside the machine the
cloth is wound on to a 600 mm diameter cloth beam. External
cloth beam on to batching motion upto 1800 mm cloth roll
diameter is also available. The required pick density can be
programmed on the microprocessor keyboard or the jacquard
control unit. The accuracy of the setting ensures easy to
adjust of the pick density of the fabric for optimum fabric
weight and minimum yarn consumption. The electronic
take-up also makes it possible to weave fabric with variable
pick densities[2,6].
11
8. Drive to the Reed and Rapier
The rapier drive system is derived from positive cams,
manufactured from a single piece of steel, which also in-
corporates the cams for the sley drive. High speeds are pos-
sible due to the special profile of the cams governing the
movement laws of the rapier[16]. The profile is designed to
transmit the lowest possible acceleration to the filling yarns.
In Dornier rapier weaving machine, type PS, the rapier and
reed are driven through gearboxes with complementary cam
assemblies with exceptionally precise control. Two high-
precision synchronized gearboxes, one at each side of the
machine, provide the drive for the filling system and reed
beat-up. The compact construction and massive drive di-
mensioned components create little vibration and a high
degree of functionality, thus achieving a secure centre
transfer of the filling. A continuous lubrication system pro-
vides for increased performance, low maintenance, and high
longevity of the new gearbox generation[1,7]. Picanol has
developed the oscillating rotational motion of the rapier
wheel generated by a simple, robust, three-dimensional
crank system, ensuring reliability, and requiring no mainte-
nance or adjustment. The sley is driven by a set of comple-
mentary cams with cam followers on both sides of the ma-
chine. They run in an ion bath connected to the central lu-
brication system. The sley with the reed holder is perfectly
balanced and provides a powerful beat-up over the whole
weaving and ensuring less vibration. When weaving heavy
and densely beaten fabrics, the machines sley system has a
strategic role[5, 6, 9]. For this reason, Leonardo developed
several sley drive units (two for narrow loom and three for
double-width machine) fixed on the main cross bar and
coupled to the connecting shafts. The optimized geometry of
the kinematics, strengthening of the camshafts in the balan-
cer and cam-reading shaft, centralized lubrication for the
drive units all these help to guarantee big advantages in terms
of stability, lower noise levels and low maintenance re-
quirement.
Figure 4. Moto Leno[7]
12 Subhankar Maity et al.: Recent Developments in Rapier Weaving Machines in Textiles
9. Selvedge
There is more than one technology available for producing
selvedge in modern high speed rapier looms. These are Moto
leno, ELSY, disco leno, power leno has been used by dif-
ferent machinery manufacturer. Dornier offers revolutionary
selvedge formation device with decisive advantages. The,
2end full-turn leno type Moto Leno, controlled in direct
relation with weave requirements, variations in pick density
and fabric construction, is freely programmable. Warp end
breaks in the selvedge area are significantly reduced. The
inexpensive alternative to tucked selvedge is the 2-end full
turn leno type Moto Leno with synchronous motor drive.
Figure 5. Disco leno[7]
Based on Moto Leno, the modular designed Moto Eco
double-disc leno is also available. While one leno forms the
fabric selvedge, the second leno replaces the catch selvedge.
All the functions are easily set directly on the machine dis-
play. In the DiscoLeno, the company presents a 2-thread
full-cross leno device with synchronous motor drive, a fea-
ture unique in the construction of weaving machines. It op-
erates with normal king and flanged bobbins and copes under
weave control with any pick density variation and fabric
construction. The advantages both in terms of machine and
weaving technology of Moto Leno and Disco Leno are fol-
lowing
● Wear-free operation at maximum speeds of up to 1200
rpm.
● The use of any types of bobbins.
● Full reversibility of the leno device.
● Simple leno threads monitoring by means of conven-
tional warp stop motion droppers.
● Use of full leno device for all types of fabric.
● Shed closing can be chosen freely in the display sepa-
rately for each leno device.
● Elimination of 2 base heald frames including drive.
● Reduction in leno yarn breaks to an absolute minimum
due to short front shed and low stress on leno thread.
● QSC-compatible. The leno devices remain as an
autonomous device when a style change is introduced on the
weaving machine.
● No bulking of the fabric selvedges caused by the leno
device, no differences in tension relative to the fabric sel-
vedge.
● Good and stable interlacing thanks to full leno tech-
nique.
● Can be used without any limit on the number of heald
frames.
● Can be retrofitted with the CAN-bus control system.
PowerLeno is a completely new technology for producing
leno fabrics. The core elements of this innovation are the
guide bar and the eyeleted reed. They replace the costly,
wear-prone leno healds used hitherto, creating the conditions
for moving into a new dimension of productivity and high
efficiency in modern weaving.
Figure 6. power Leno[10]
The working principle is like that.
● The leno thread (blue) runs through the apertures in the
guide bar and eyeleted reed; the stationary end (red) has been
drawn into the eyelet of the eyeleted reed. The shed is open
for weft insertion.
● Following weft insertion the guide bar moves upward;
the eyeleted reed moves in the opposite direction until the
leno thread is above the stationary end.
● Now the guide bar is displaced sideways until the leno
thread is on the opposite side of the aperture in the eyeleted
reed. .
● Now, when the guide bar moves downward and the
 American Journal of Systems Science 2012; 1(1): 7-16
eyeleted reed upward, the leno thread comes to lie over the
stationary end.
● The shed is open for the next weft insertion. The system
is ready for the next sequence in the opposite direction.
PowerLeno sets the new standard for cost effective pro-
duction of leno fabrics. PowerLeno means higher produc-
tivity coupled with a degree of reliability never previously
achieved. PowerLeno gives:
Optimum fabric quality and maximum efficiency thanks
to reduced yarn loading
● User-friendliness, with easy, straightforward machine
operation
● A wide range of applications, with working widths up to
540 cm
● Increased productivity thanks to maximum machine
performance
● Minimal wear thanks to low masses and less movement
● Higher overall cost-effectiveness in leno fabric produc-
tion.
Picanol has developed the unique ELSY full leno selvedge
motion, electronically driven by individual steeper motors.
The selvedge crossing can be programmed or the micro-
processor independently of the shed crossing even while the
machine is in operation. The earliest position for rethreading
can be set by a simple push of a button, when the machine
starts the selvedge system automatically returns to its origi-
nal position.
In Suizer G6500, the electronically controlled sel-
vedge-forming unit can be adjusted at the terminal while the
machine is running. The selvedge forming units are sepa-
rately driven and ensure clean selvedge formation. The
timing of the shed closure for the left and right selvedges is
freely programmable via the terminals[5,10,12,32].
10. Quick Style Change
The quick style change system, developed by several ra-
pier weaving machine manufacturers in their own versions
Figure 7. Automatric start mark prevention[7]
13
ensures quick style change (less than 30 min). With quick
style change just one person can carry out a style change in
less than 30min. This is achieved by swapping the whole
back part of split frame, with the warp beam, the back rest
and the supports, the warp stop motion the harness and the
reed. This ultimately increases the productivity of the loom
shed. The quick style change system is not just a machine
set-up but also an integrated system that allows the move-
ment of the preparation room of some operations normally
done on the weaving machine. The knotting operations and
the drawing-in of the warp can be done in the preparation
department, thus improving the workload and avoiding
longer machine downtime.
Leonardo is integrated with the "VQSC" Quick Style
Change System, which ensures reduced machine downtime
and the extra time needed to unload the machine, to adjust
the setting and to load the new style as far as possible. Also
the warp stop motion, frame, reed, and beam unload-
ing/loading operation have been made far easier with the
introduction of rational and reliable technical solution.
Picanol developed QSC, Quick Style Change System in
which the style change is achieved by swapping the whole
back part of the split frame, with the warp beam, the back rest
and the supporting warp stop motion, the harnesses, and the
reed. Additionally this unique system makes it possible to
carry out the entire article related setting on the warp side,
outside the weaving shed before the style change. This ul-
timately reduces the labor requirement and thus increases the
loom efficiency[1, 6, 7, 9, 12, 33] with the following benefits
and advantages;.
● Reduce machine down time.
● Interference losses due to simultaneous stops are prac-
tically non-existent.
● Fewer personal required for warp and article changes in
weave room.
● Warp changes can be replaced by style changes, ena-
bling the load on the tying and drawing in equipment to be
balanced instead of having two bottlenecks.
14 Subhankar Maity et al.: Recent Developments in Rapier Weaving Machines in Textiles
11. Automatic Start Mark Prevention
Automatic Start-mark Prevention (ASP) prevents starts
mark at the source. The simple functionality of automatic
start-mark prevention saves time and significantly contrib-
utes toward quality improvement. All the functions outlined
in the illustration can be simply called up on the machine
display and change as required.
12. Electronic Control Technology
The electronics of modern rapier weaving machine are
based on multiprocessor architecture with 32-bit technology.
Data transfer between the various sub units of the machine is
via a CAN- BUS[17], permitting fast and reliable exchange
of data both internally and externally. The terminal has a
graphic display in which various functions of the warp let-off,
cloth take-up, weft feeder, etc, can be programmed easily
and. clearly. The modern electronics give the following
advantages:
● Ease of operation.
● High fabric quality irrespective of speed.
● Pick density alterable while the machine is in operation.
● Immediate help trouble-shooting problem.
● Self-adjusting stop position of the machine.
● Microprocessor controlled central forced lubrication
system.
● Storage and monitoring of all the production data, effi-
ciently.
● Machine function control, pattern weave, warps tension,
pick density.
● Pick finding control and the elimination of stop marks
by means of pro-set programs.
● Control and report of style change timing.
● Quick control of the electronic functions (self diagnos-
tics and auto check up) and monitoring of the machinery
functions for protection[18-20].
● Bi-directional communication between the weaving
machine and the central production computer.
● Speed set-up.
● Electronic weaving speed variation depending on the
characteristic of the yarn being used.
● Control of warp let-off and fabric take-up.
● Electronic control of the filling tension.
● Transfer of setting and production parameters of a fabric
style, to other machine with the help of memory cards.
In Picanol GamMax, most of the machine functions are
digitally controlled. All the machine settings can be digitally
stored and transferred. The electronic terminal on GamMax
monitors and controls all machine functions. Its LCD screen
has self explanatory menus and enables the weaver to set the
weaving parameters in a very user-friendly way. GamMax is
also Internet- enabled. The GamMax terminal features
wireless communication through a USB memory stick or key
tag, permitting robust, flexible, handy and reliable operation.
Suizer G6500 offers "Smart Weave" - intelligent pattern data
programming. "Smart Weave" offers fabric designer intel-
ligent support in the preparation of weaves design and picks
repeats. The G6500 control interface is a user-friendly,
Internet-ready touch screen terminals. The logical structur-
ing with self-explanatory Pictogram guides the operators to
the desired function simply and with a minimum of keying.
In Leonardo, the computer system is based on the CAN-BUS
system. This drives and controls all the main textile and
mechanical function. With the CAN-BUS in mind, a new
controller has been developed, called the FULLTRONIC.
This co-ordinate all loom functions instant by instant, from
the operating conditions of the various mechanisms to each
individual response: heald movement, color to be selected,
warp tension, density of the weft in the fabric, plus the
messages describing the status of the lubrication circuit.
Monitoring takes place at a frequency of more than 700
messages/sec.
The Dornier rapier-weaving machine, type PS, has control
cabinet with integrated CANBUS and various modules for
start, stop, warp let-off and fabric take-up as well as start
mark prevention. The Dornier Customer Service Department
can directly access machine displays - trouble shooting
online. The DoNet Global Communication Network offers
quick location and transportation of setting instructions,
remote diagnostics[1,2,6,7,9,25].
13. Machine Main Drive
The Dornier rapier-weaving machine is driven with a
continuously running motor over a magnetic brake-clutch
unit. Intelligent electronics monitor the acceleration time and
control the exceptionally short brakes time. This guarantees
the full dynamics of reed beat-up on the first pick, thus
eliminating start mark. Picanol has developed the Sumo
main motor. It drives the weaving machine directly, without
belt transmission or clutch and brake. The machine speed is
controlled electronically, which considerably reduces the
setting time. With the Sumo motor it is possible to continu-
ously adapt the machine speed pick-by-pick to match the
strength of the filling yarn. With the help of this system, it is
no longer necessary to keep the machine speed continuously
low if there is one weaker filling yarn in multi-channel
weaving. With the Sumo motor it is possible to continuously
adapt the machine speed pick-by-pick to match the strength
of the filling yarn. With the help of this system, it is no longer
necessary to keep the machine speed continuously low if
there is one weaker filling yarn in multi-channel weaving.
The advantages of Sumo motor are -
● Saving on energy consumption of more than 10% in
comparison with conventional clutch and brake configura-
tion.
● Machine speed setting is done accurately and com-
pletely, electronically via the keyboard of microprocessor.
This reduces the setting time to zero.
● Speed setting is easy to copy to other machine either
with electronic set card or with production computer with
 American Journal of Systems Science 2012; 1(1): 7-16
bi-directional communication.
● Automatic pick finding becomes faster, which signifi-
cantly reduces the down times for repairing filling and warp
breakages.
● The machine can always work at optimum weaving
speed in function of quality of the yarn, the number of frames,
and fabric construction[5-7,9,11,24].
14. Conclusions
Today’s rapier weaving machine has become fast and
exceptionally flexible. It offers a choice of various reed
widths, shedding motions, selvedges and filling insertion
colors etc. The weft color selectors of today’s rapier weaving
machine are microprocessor controlled, compact sized ones
and can be available in up to 16 colors[21]. The maximum
weft insertion rate achieved is 1620 m/min. The versatile
rapier head van handle a count range lies between 0.77 tex
and 3333 tex. Rapier head has become smaller, lighter and
able to free-flight. Filling insertion system is microprocessor
controlled and synchronized with other mechanisms. Shed-
ding mechanism has become more versatile. Let-off and
take-up mechanism is synchronized with other mechanisms
so that minimum start-up marks produced in fabric in large
diameter of take-up roll[22-23]. Drive mechanism to reed
and rapier provides minimum acceleration to the filling so
that minimum filling breaks occur. Fully programmable high
speed selvedge formation devices such as Moto leno, Disco
leno, Power leno and ELSY are developed to cope up with
high speed rapier machines.
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